Corrosion inhibitor barrier for ferrous and non-ferrous metals

ABSTRACT

An environmentally friendly corrosion inhibiting formulation for the oil-water interface of pipe lines and oil well drilling systems which is prepared pursuant to a process including the steps of reacting a fatty acid anhydride selected from the group consisting of a fatty acid anhydride and a 21 carbon dibasic acid with an amine or imidazoline to form a corrosion inhibitor consisting essentially of a fatty acid derivative; dissolving the inhibitor in a fatty acid oil or ester selected from the group consisting of soybean oil or methyl soya ester; adding water dispersing agents consisting of sulfonates and a long chain ethoxylated alcohol; and adjusting the viscosity with an alcohol comprising isopropanol.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to an improved corrosion protection system that incorporates selected corrosion inhibitors, blended with water dispersants and dissolved in a biodegradable solvent. Effective for a wide range of refined hydrocarbons, crude and oil/water combinations the system forms an effective corrosion-inhibiting barrier for both ferrous and non-ferrous metals in the presence of water, halogens and corrosive gasses such as dissolved oxygen, sulfur dioxide, carbon dioxide and hydrogen sulfide.

[0002] Continuing protection between individual treatment operations is assured due to solubility, dispersibility in crude water mixtures, and the long-term water displacing film formation. The product also provides vapor phase inhibition to protect areas which are inaccessible through direct solution contact. This unique characteristic protects internal parts during low fluid levels and combats atmospheric corrosion in production and storage tanks. Crude oil processing equipment, pipes and pipelines, refinery equipment and systems can be effectively protected against pitting, corrosive gases and water intrusions. Field test applications performed by independent laboratories verify that tests indicate that products pursuant to the invention are highly effective at a concentration level as low as 5-15 ppm. This system will find good acceptance as the use of a biodegradable solvent such as the methyl ester of soya fatty acid provides a much more environmentally friendly system.

[0003] A recent article in Materials Performance, a technical journal published by the NACE (National Association of Corrosion Engineering) stated while industry and suppliers had made progress in improving green inhibitors the industry must contend with a number of technical issues related to effectiveness and regulatory issues that vary from region to region.

[0004] The development of “green” inhibitors are in direct response to several different standards that have been established in regions of the world and the UK focused on a system callled (OCNS) a notification system. Other countries of the North Sea region have selected a system that also included risk management called CHARM.

[0005] As a result of conflicting systems or the lack of one a “green” inhibitor may have different shades of green.

[0006] The North Sea group has the best-defined regulations as follows:

[0007] Biodegradability: >60% in 28 days

[0008] Marine toxicity: Effective Concentration, 50% (EC50)/Lethal Concentration, 50% (LC50) >10 mg/L to North Sea species

[0009] Bioaccumulation: Log Octanol/Water Partition Coefficient (Pow) <3.

SUMMARY OF THE INVENTION

[0010] This new system provides a method and process including addition of a biodegradable corrosion inhibiting system without the extreme care needed in handling conventional mineral oil systems in environmentally protected areas. The criteria that operators must follow in the North Sea (UK, Norway, Denmark, The Netherlands) are very definite and this new inhibitor system dissolved in the methyl ester of soya fatty acid meets all of the specifications. Fatty acid triglycerides such as soy bean oil, canola oil, linseed oil or other glycerides could also be the carrier and need only viscosity or formulation adjustments to provide corrosion inhibitor systems.

EXAMPLE 1

[0011] The corrosion inhibitor system used in this new formulation of the invention is specially formulated to be effective in either the oil or the water phase when used in pipeline or drilling applications.

[0012] A blend of surfactants, carrier, dispersant and corrosion inhibitor was prepared from the following ingredients: Parts by Weight Component 40 parts methyl soya fatty acid ester  5 parts ethoxylated alcohol  8 parts sodium sulfonate 15 parts Westvaco 1550 diacid 15 parts Imidazoline 17 parts Isopropanol.

[0013] The Westvaco acid component, which is a 21 carbon dicarboxylic acid derived from tall oil fatty acid, reacts with imidazoline to form a salt that functions as a corrosion inhibiting barrier giving persistent long-term protection. This material is commercially available.

EXAMPLE 2

[0014] A blend of carrier, surfactants, dispersant and corrosion inhibitor was prepared from the following ingredients. Tenax 2010 supplied commercially by Westvaco is a fatty acid anhydride. Parts by Weight Component 50 parts methyl soya fatty acid ester  5 parts ethoxylated alcohol 10 parts sodium sulfonate 15 parts Tenax 2010 reacted with 2- amino 2-methyl propanol 20 parts Isopropanol.

[0015] The systems are oil soluble due to the fatty acid component of the inhibitor and water brine dispersable due to the ethoxylated sulfonated additions. The Isopropanol is added to reduce the viscosity. In use concentrations of 5-15 ppm are suitable for either pipelines, oil wells or other equipment.

EXAMPLE 3

[0016] A water dispersable and oil soluble system can be produced by utilizing the maleic anhydride addition of a fatty acid, which is available commercially from Westvaco as Tenax 2010. This anhydride addition product reacts with amines, alcohols or imidazoline to produce biodegradable inhibitors or can be hydrolyzed with water to provide three carboxyl groups. Parts by Weight Component 15 parts Fatty acid anhydride (Tenax 2010) 15 parts Imidazoline 40 parts soy bean oil 10 parts Ethoxylated alcohol  5 parts sodium sulfonate 15 parts Isopropanol.

EXAMPLE 4

[0017] A blend of carrier, surfactants, dispersants and corrosion inhibitor was prepared with Henkel EMPOL 1008, available commercially, a dimer acid prepared from fatty acids. Parts by Weight Component 20 parts Henkel EMPOL 1008 20 parts 2-amino-2-methyl-1-propanol 40 parts Methyl soya fatty acid ester  8 parts Sodium sulfonate 12 parts Isopropanol.

[0018] The fatty acid portion of the inhibitor functions as a corrosion barrier at a pipe surface and the sulfonate and isopropanol assists in dispersing the inhibitor into either the water or oil phase.

Corrosion Testing

[0019] All tests were performed on the basis of those components of Example 1 hereinabove.

Wheel Oven Test

[0020] The wheel oven test was conducted at 160° F. (71° C.) for 48 hours with the following results: Concentration, ppm Effectiveness, % 5 92.3 25 95.5 100 98.7

Emulsion Tendency

[0021] Conditions of the emulsion tendency test were as follows:

[0022] Concentration: 100 ppm

[0023] Water: Crude Oil=80:20

[0024] Temperature: 180° F. (82° C.) % of Emulsion 5 min 15 min 30 min Example 1 8 8 8 Blank 6 6 6

Dynamic Circuit Test

[0025] Loop Operating Conditions: Temperature Ambient Velocity 6-8 m/min Pressure 2-3 psi Material Carbons Steel 1010 Brine NaCl 5% CH₃OOH 0.5% H₂S (saturated) Test Timing 24 hours Inhibitor Dose 50 ppm Effectiveness 78% (polarization resistance technique)

Prevention of Stress Corrosion Cracking

[0026] NACE TM-01-77 Procedure:

[0027] Condition of the test:

[0028] Concentration of Example 1-200 ppm

[0029] Steel—ANSI 1045-1018 annealed

[0030] Load—12000 psi (843 kg.cm²) Product Time to Failure, days Example 1 >30 Blank 8

[0031] The criteria that has been established for environmentally friendly corrosion inhibitors system for the North Sea (UK, Norway, Denmark and the Netherlands) maybe the most stringent of any global regulations and when the preparation described in Example 1 was evaluated, the results were within these limits.

Sample A Environmental Testing Biodegradability, %

[0032] 5 days 10 days 25 days 39.3% 52.4% >60%

Toxicity

[0033] 48 hour Static Renewal

[0034] Mysidopsis Bahia Definitive Toxicity Test Result (EPA/600/4-90/027F) data NOEC*/LOEC**, LC50, ppm CTS, ppm CTS*** M. bahia M. bahia**** 1000 ppm/3000 ppm 1511.6

[0035] ** The Lowest Observable Effect Concentration is the lowest concentration tested that does significantly reduce survival of the exposed organisms.

[0036] *** The Chemically Treated Seawater

[0037] **** LC 50—effective concentration to kill 50° of the aquatic organism population (Limits >100 ppm)

[0038] The new inhibitor system described in this application easily meet the specification of biodegradability due to the high percentage of a bio-based solvent and an inhibitor that is derived from a fatty acid base that functions as the inhibitor and forms a protective film of absorbed molecules in the pipe that acts as a barrier to corrosive elements. 

What is claimed:
 1. An environmentally friendly corrosion inhibiting formulation for the oil-water interface of pipe lines and oil well drilling systems which is prepared pursuant to a process including the steps of: (a) deriving a reactant by reacting a component selected from the group consisting of a fatty acid anhydride and a 21 carbon dibasic acid with an amine or imidazoline to form a corrosion inhibitor consisting essentially of a fatty acid derivative; (b) dissolving the inhibitor in a fatty acid oil or ester selected from the group consisting of soybean oil or methyl soya ester; (c) adding water dispersing agents consisting of sulfonates and a long chain ethoxylated alcohol; and (d) adjusting the viscosity with an alcohol comprising isopropanol.
 2. A corrosion inhibiting formulation prepared from a dibasic acid reacted with imidazoline which is dissolved in the methyl ester of soya fatty acid; water dispersing agents such as sodium sulfonate, ethoxylated alcohol and isopropanol complete the system.
 3. The environmentally friendly corrosion inhibiting system of claim 1 that will biodegrade at least 60% in about 28 days is oil soluble and water dispersable and is used as follows: Type of Type of System Corrosive to be Protected Medium Technology of Application Pipelines Separate crude Method of Frequency of and oil/water Application Application collection mixtures with and Dosage systems a level of Continuous Intermittent for water- encroachment injection treatment: encroached up to 98%. of 5-15 ppm 1,700-3,500 ppm crude oil CO₂ - varying during a concentration 48 hr. H₂S - up to period 4 6,000 ppm times/year Oil wells Crude with a Injection Periodic and high level of of the injection of equipment water inhibitor 400-1,500 ppm encroachment into the every 2-2½ and high clearance months. concentrations hole (5-15 ppm) of CO₂ and H₂S. 